Hard anodize of cold spray aluminum layer

ABSTRACT

A process for repairing components includes the steps of providing a component having an affected area on a surface of a component to be repaired; depositing a repair material over the affected area on the surface of the component so that the repair material plastically deforms without melting and bonds to the affected area upon impact with the affected area and thereby covers the affected area; providing a sulfuric acid based anodizing solution; anodizing a deposited repair material on the surface of said component in the sulfuric acid based anodizing solution; consuming only a portion of the deposited repair material to form a hard anodized coating layer upon the deposited repair material to form a hard anodized coated component; providing a corrosion resistant sealant solution; and contacting a hard anodized coated component with the corrosion resistant sealant solution to form a corrosion resistant sealant coating on the hard anodized coated component.

FIELD OF THE DISCLOSURE

The invention relates to the field of repairing gas turbine componentsthat have experienced corrosion damage and, more particularly, relatesto methods that extend component life by reducing or eliminating furthercorrosion damage which could cause the component to be scrapped.

BACKGROUND OF THE DISCLOSURE

Gas turbine engine components, such as fan cases, bleed valves, bleedducts, clamps, nacelle v-grooves, nacelle track sliders, gearboxes, andthe like, are typically constructed of aluminum and magnesium alloys.Aluminum alloys such as AA 6061 and AA 2024 are soft and suffer damagevia general wear, fretting against steel components, impact, etc. Onemethod of mitigating wear of aluminum alloys is anodic conversion of thealloy to produce a hard oxide layer on the exposed surface per processessuch as AMS 2468 or AMS 2469. There exist many means to dimensionallyrestore aluminum alloys; however, wear resistance is inferior to thesehard anodic coatings.

Aluminum alloys are susceptible to general corrosion and especially salt(halide) environments and galvanic corrosion during regular service inthe field. And, magnesium alloys, being typically less noble thanaluminum alloys, are actually more susceptible to galvanic corrosion.For example, corrosion damage can be caused from electrical contact witha more noble alloy or by electrolytes in the presence of water ormoisture. Environmental conditions such as chemical fallout, saltwater,and others can accelerate corrosion or add additional corrosionprocesses. Hard anodic layers provide some corrosion protection,especially when sealed with corrosion inhibiting materials, e.g.,chromium conversion coatings.

There exists a drawback to hard anodizing processes. Hard anodizingprocesses consume part of the components' surface. The hard anodizeprocess adds thickness to the surface, but the interface between anodizesurface and parent alloy moves in to the parent material toapproximately an equivalent thickness when forming a hard anodized layer8 and repairing the component 6 (See FIG. 1). The rework of the anodiclayer requires that all prior layer be removed. This limits the numberof times the hard anodized layer may be applied in the rework and repairof the component. Magnesium alloys can be hard anodized, but theprocesses are substantially more difficult and expensive.

What is desired is a method of repairing gas turbine components thathave suffered wear and corrosive deterioration by identifying andmitigating the corrosion attack before the component wall thickness hasdeteriorated below that required to provide minimum strengthrequirements, and restoring the original component dimensions whilerestoring original or offering added wear resistance and corrosionprotection.

SUMMARY OF THE DISCLOSURE

In accordance with one aspect of the present disclosure, a process forrepairing components, broadly comprises the steps of providing acomponent having an affected area on a surface of a component to berepaired; depositing a repair material over the affected area on thesurface of the component so that the repair material plastically deformswithout melting and bonds to the affected area upon impact with theaffected area and thereby covers the affected area; providing a sulfuricacid based anodizing solution; anodizing a deposited repair material onsaid surface of said component in said sulfuric acid based anodizingsolution; consuming only a portion of said deposited repair material toform a hard anodized coating layer upon said deposited repair materialto form a hard anodized coated component; providing a corrosionresistant sealant solution; and contacting a hard anodized coatedcomponent with the corrosion resistant sealant solution to form acorrosion resistant sealant coating on the hard anodized coatedcomponent.

In accordance with another aspect of the present disclosure, a repairedcomponent broadly comprises a component including a surface having acold sprayed layer of repair material disposed thereupon, the componentfurther includes an original thickness and the surface includes arestored thickness; and an anodized, hard coat disposed upon the coldsprayed layer, wherein the original thickness is a thickness of thecomponent prior to applying the cold sprayed layer and the restoredthickness is the original thickness combined with a thickness of thecold sprayed layer.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representation of a substrate surface being consumed duringa hard anodizing process of the prior art.

FIG. 2 is a flowchart representing an exemplary process for the hardanodize of cold spray aluminum layer on a substrate;

FIG. 3 is a representation of a cold spraying deposition apparatus foruse in the process described herein;

FIG. 4 are a set of four (4) microphotographs at differentmagnifications showing a comparison of a metallographic examination ofthe bond line between the cold spray layer and substrate of an anodized6061 aluminum alloy plate cold sprayed with 6061 aluminum (unsealed);

FIG. 5 are a set of four (4) microphotographs at differentmagnifications showing a comparison of a metallographic examination ofthe bond line between the cold spray layer and substrate of an anodized6061 aluminum alloy plate cold sprayed with 6061 aluminum (sealed) afterundergoing salt fog testing (ASTM B-117) for approximately 336 hours;

FIG. 6 are a set of four (4) microphotographs at differentmagnifications showing a comparison of a metallographic examination ofthe junction area of a hard coating and the substrate of an 6061aluminum alloy plate cold sprayed with 6061 aluminum after undergoingsalt fog testing (ASTM B-117) for approximately 336 hours; and

FIG. 7 is a representation of an exemplary hard anodized componenthaving a hard oxidized layer deposited upon a cold spray layer coveringthe surface of the component.

Like reference numbers and designations in the various drawings indicatelike elements.

DETAILED DESCRIPTION OF THE DISCLOSURE

Over the last several years, a technique known as cold gas dynamicspraying (“cold spray”) has been developed. This technique isadvantageous in that it provides sufficient energy to accelerateparticles to high enough velocities such that, upon impact during aninitial pass, the particles plastically deform and bond to the surfaceof the component on which they are being deposited so as to build arelatively dense coating or structural deposit. On subsequent passes,the particles bond to the previously deposited layer. Cold spray doesnot metallurgically transform the particles from their solid state. Thecold spray process has been found to be most useful in effecting repairsof components formed from ductile materials. For example, the cold sprayprocess may be used during the repair of turbine engine components, suchas a fan exit inner case or a gearbox, formed from aluminum or magnesiumbased materials. One such suitable cold spraying process is disclosed inU.S. Pat. Publ. No. 2006/0134320 to DeBiccari et al., and assigned toUnited Technologies Corporation, the assignee of the presentapplication, is incorporated herein by reference in its entirety.

The process described herein restores the coating of an affected area onthe surface of a component without consuming the surface, that is, theoriginal thickness, of the component. As known to one of ordinary skillin the art, hard anodizing processes alone can consume parent alloy upto fifty percent (50%) of the anodic layer. The inventors of the presentapplication discovered first depositing a repair material via, forexample, cold spray deposition techniques, and then anodizing therepaired component actually preserved the original thickness of thecomponent while in turn imparting wear resistance and corrosionprotection. The inventors also discovered this process is effective forproviding economical hard anodize protection to magnesium alloys. Thehard anodic conversion processes are not easily or economically appliedto magnesium alloys.

The inventors discovered by first applying cold sprayed aluminum tomagnesium alloy based components, hard anodic conversion and chromateconversion coatings may be applied and the advantages and benefitsachieved as disclosed herein. Moreover, there are benefits andadvantages beyond the application to aluminum and magnesium basedalloys. As the cold spray is a mechanical bonded substrate, the coldspray material may be applied to more expensive alloys or alloys knownto be difficult to apply hard anodized coatings upon and be subsequentlyhard anodized more efficiently.

FIG. 2 shows a flowchart illustrating an exemplary process of thepresent disclosure.

A component composed of a magnesium alloy, aluminum alloy, conductivealloys, combinations comprising at least one of the foregoing alloys,and the like, and having an exterior surface is provided. Representativealuminum alloys for cold spray deposition include but are not limited to1000 series, 5000 series and 6000 series. The component may be a gasturbine engine such as fan cases, bleed valves, bleed ducts, clamps,nacelle v-grooves, nacelle track sliders, gearboxes, and the like. Thecomponent may be inspected for damage at step 10 using any one of anumber of techniques known to one of ordinary skill in the art. At thesame time the material composition of the component may also bedetermined at step 12 using any one of a number of techniques known toone of ordinary skill in the art.

When repairing a turbine engine component, corrosion pits and/or damagedareas are mechanically removed (step 14) through grinding, machining, orother applicable techniques known to one of ordinary skill in the art.The resultant surface area may be cleaned using a chemical basedcleaning technique (step 16) known to one of ordinary skill in the art.Afterwards, the chemically cleaned surface area of the component may beprepared for cold spray deposition (step 18) using a grit blastingtechnique known to one of ordinary skill in the art.

Referring now to FIG. 3, there is shown a system for carrying out a coldspray process on an affected area 44 of a component or a part. Arepresentative cold spray process is disclosed in U.S. patentapplication Ser. No. 11/825,384 to Bunting et al., assigned to UnitedTechnologies Corporation and incorporated herein by reference in itsentirety. Another representative process is disclosed in United StatesPatent Publication No. 2006/0134320 to DeBiccari et al., and assigned toUnited Technologies Corporation, the assignee of the presentapplication, is incorporated herein by reference in its entirety.

The system includes a spray gun 42 having a converging/diverging nozzle40 through which the repair material is sprayed onto an affected area ofa surface 45 of the component 60 to be repaired. During deposition ofthe repair material, the component 60 may be held stationary or may bearticulated or translated by any suitable means (not shown) known in theart. Alternatively, spray nozzle 40 may be held stationary or may bearticulated or translated. In some situations, both the part and thenozzle may be manipulated.

Suitable aluminum containing materials which may be used to effectrepairs in accordance with the process described herein, but are notlimited to, pure aluminum, aluminum alloy 6061, aluminum alloy 2219,Al-12Si alloy, Al—Sc alloy, aluminum alloy 6061/B4C, and aluminum alloy5056. In a preferred embodiment of the present invention, the aluminumcontaining material comprises a material which has a composition thatincludes more than 50% by weight of aluminum.

In the cold spray process described herein, the repair materialfeedstock may be a powdered aluminum containing material 51. Thepowdered aluminum containing material may be a powdered aluminumcontaining material of −325 mesh with particle sizes in the range offrom 5 microns to 50 microns. Smaller particle sizes such as thosementioned before enable the achievement of higher particle velocities.Below 5 microns in diameter, the particles risk getting swept away fromthe surface 45 and/or the affected area 44 due to a bow shock layerabove the surface 45 and/or the affected area 44. This is due toinsufficient mass to propel the particles through the bow shock. Thenarrower the particle size distribution, the more uniform the particlevelocity will be. This is because if one has large and small particles(bi-modal), the small ones will hit the slower, larger ones andeffectively reduce the velocity of both.

The fine particles of the aluminum containing repair material may beaccelerated to supersonic velocities using compressed gas, such ashelium, nitrogen, or other inert gases, and mixtures thereof. Helium andnitrogen are preferred gases because both helium and nitrogen producethe highest velocity due to their low molecular weights.

The bonding mechanism employed by the method of the present inventionfor transforming the powdered aluminum containing repair material into adeposit is strictly solid state, meaning that the particles plasticallydeform. Any oxide layer that is formed on the particles and/or on thecomponent surface is broken up and fresh metal-to-metal contact is madeat very high pressures.

The powdered aluminum containing repair material used to form thedeposit may be fed to the spray gun 42 using any suitable means known inthe art, such as modified thermal spray feeders. For example, a Praxair®powder feeder at a wheel speed of 1-5 rpm may be used.

In the process described herein, the feeder may be pressurized with agas 53 selected from the group consisting of helium, nitrogen, or otherinert gases, and mixtures thereof. For example, the feeder may bepressurized using helium at a pressure in the range from 200 psi to 400psi, preferably from 300 to 350 psi. The main gas is preferably heatedso that the gas temperatures is in a range from 250° C. (482° F.) to550° C. (1022° F.), preferably from 350° C. (662° F.) to 450° C. (842°F.). In the alternative, the feeder may be pressurized using nitrogengas at a pressure in a range from 400 psi to 600 psi, preferably from500 psi to 550 psi. When using nitrogen gas, the main gas is alsopreferably heated so that the gas temperature is in a range from 250° C.(482° F.) to 550° C. (1022° F.), preferably from 350° C. (662° F.) to450° C. (842° F.).

The gas may be heated to keep it from rapidly cooling and freezing onceit expands past the throat of nozzle 20. The net effect is a surfacetemperature on the part being repaired of about 46° C. (115° F.) duringdeposition. Any suitable means known in the art may be used to heat thegas.

To deposit the aluminum containing repair material, the nozzle 40 maypass over the affected area 44 of the part 60 being repaired more thanonce. The number of passes required is a function of the thickness ofthe repair material to be applied. The method of the present inventionis capable of forming a deposit having any desired thickness. If onewants to form a thick layer, the spray gun 42 may be held stationary toform a thick deposit over the affected area 44. When building a depositlayer of the aluminum containing repair material, it is desirable tolimit the thickness per pass in order to avoid a quick build up ofresidual stresses and unwanted debonding between deposit layers.

The main gas that is used to deposit the particles of the repairmaterial over the affected area 44 may be passed through the nozzle 40via an inlet 50 at a flow rate of 0.001 SCFM to 60 SCFM, preferably inthe range of 15 SCFM to 50 SCFM. The foregoing flow rates are usefulwhen either helium or nitrogen is used as the main gas.

The pressure of the spray gun 42 may be in the range of from 200 psi to400 psi, preferably from 300 psi to 350 psi. The powdered aluminumcontaining repair material is preferably fed from a hopper, which isunder a pressure in the range of 10 to 50 psi higher than the specificmain gas pressure, preferably 15 psi higher to the spray gun 42 via line54 at a feed rate in the range of 10 grams/min to 100 grams/min,preferably 15 grams/min to 50 grams/min.

The powdered aluminum containing repair material is preferably fed tothe spray gun 42 using a non-oxidizing carrier gas. The carrier gas maybe introduced via inlet 50 at a flow rate of 0.001 SCFM to 50 SCFM,preferably 1 SCFM to 15 SCFM. The foregoing flow rates are useful wheneither helium or nitrogen is used as the carrier gas.

The spray nozzle 20 is held at a distance from the affected area 24.This distance is known as the spray distance. Preferably, the spraydistance is in the range of 10 mm to 50 mm. The velocity of the powderedrepair material particles leaving the spray nozzle 20 may be in a rangefrom 825 m/s to 1400 m/s, preferably from 850 m/s to 1200 m/s. Thedeposit thickness per pass may be in the range of 0.001 inches to 0.030inches.

Using the process described herein, the aluminum containing repairmaterial, such as aluminum alloy 6061, may be cold sprayed (step 20)over the affected area on the component 60 to a thickness above theoriginal wall thickness. After the aluminum containing material has beendeposited, the component 60 may undergo stress relief, for example, heattreatment, at step 22 as known to one ordinary skill in the art.

Stress relief techniques are typically performed to recover theductility of the cold sprayed aluminum containing repair material. Thestress relief step may be carried out at a temperature which achievesthe desired ductility for the component 60. For example, the heattreatment may be one in which the component with the cold sprayedaluminum containing material deposit is heated in an air oven to atemperature of 260° C. (500° F.) for a time period of 1 hour to 2 hours.When some aluminum containing repair materials are used, no heattreatment may be needed. When other aluminum containing repair materialsare used, the heat treatment may be at a temperature which varies from38° C. (100° F.) to a temperature greater than 260° C. (500° F.) for atime period in the range of 1 hour to 24 hours. When the componentrequires undergoing stress relief, the entire component, or the localarea of the repair, may be treated.

After step 22 is completed, the cold spray layered component 60 with thedeposited repair material may be mechanically smoothed in the region ofthe affected area 44 and structural credit may be claimed for therepaired area. Structural credit as used herein refers to the fact thatthe cold sprayed aluminum alloy repair material has a percentage of thebase material strength and repaired thickness is considered as part ofthe measured wall thickness. The cold spray layered component 60 may bepreliminarily inspected to determine whether the wear resistance issufficient at step 24. Any one of a number of suitable techniques fordetermining wear resistance known to one of ordinary skill in the artmay be utilized.

It is not necessary that the deposits of the cold sprayed aluminumcontaining repair material have parent metal strength, only that thestructural credit be sufficient such that the effective wall thicknessis above the required minimum. If the effective wall thickness is abovethe required minimum, the component 60 can be salvaged. As used herein,the term effective wall thickness means that if one considers thesprayed deposit to have 75% of the strength of the base material formingthe component 60, then the repair thickness is credited 75%. Thus, ifthe current wall thickness of the component 60 is 0.100 inches and adeposit of 0.050 inches is applied to make total thickness of 0.150inches, the effective wall thickness of the repair is 0.1375 inchessince the repair material has 75% of the strength of the base materialof the component.

If the component 60 demonstrates sufficient wear resistance, thecomponent 60 may undergo a final inspection at step 32. However, if thecomponent 60 does not demonstrate sufficient wear resistance, the coldsprayed aluminum layered component 60 then undergoes an anodizingprocess. The cold sprayed aluminum layered component 60 may be treatedto remove grease, if necessary, from the cold spray layer as known toone of ordinary skill in the art. The optional grease removal step maybe done, if necessary, prior to anodizing the cold sprayed aluminumlayer.

The term “anodized aluminum” as used herein refers to aluminum and itsalloys which have been subjected to the anodizing process to produceadherent aluminum oxide (Al₂O₃) coatings thereon. Such aluminum oxidecoatings provide hard and strong protective coatings and protect againstcorrosion and abrasion as well as strengthen the coated articles andprovide electrical insulation thereon. Presently, the process describedherein subjects the deposited cold sprayed aluminum layer to ananodizing process (step 26) known to one of ordinary skill in the art.

The anodizing process comprises anodizing the metal substrate in asulfuric acid based anodizing solution, preferably a sulfuric oxalicacid anodizing solution, at step 26. The deposited cold sprayed aluminumlayer may be subjected to a sulfuric oxalic acid anodize by any manneras known to one of ordinary skill in art. The anodizing process forms ahard oxide layer 70 upon a cold spray layer 68 of component 60 withoutconsuming the parent alloy and only consuming a portion of the coldspray layer 68 (See FIG. 7). The hard anodized component 60 may bepreliminarily inspected to determine whether the corrosion resistance issufficient at step 28. Sufficient corrosion resistance may be determinedusing any one of a number of techniques known to one of ordinary skillin the art. If the hard anodized component 60 demonstrates sufficientcorrosion resistance, the hard coated component 60 may then undergo afinal inspection at step 32. However, if the hard anodized component 60does not demonstrate sufficient corrosion resistance, the hard coatedcomponent 60 may then undergo a corrosion resistant sealant process atstep 30.

During the exemplary chromate conversion process, the hard coatedcomponent 60 may be contacted with an acidic trivalent chromiumcontaining solution to form a trivalent chrome enriched coating upon theanodized component. The acidic aqueous solution comprises a watersoluble trivalent chromium compound, a water soluble fluoride compoundand an alkaline reagent. A representative acidic aqueous solution maycomprise a trivalent chromium compound is present in an amount ofbetween 0.2 g/liter to 5 g/liter (preferably between 0.5 g/liter to 2g/liter), a fluoride compound is present in an amount of between 0.2g/liter to 5 g/liter (preferably 0.5 g/liter to 2 g/liter), and analkaline reagent is present in an amount to maintain the pH of thesolution between 3.0 to 5.0 (preferably 3.5 to 4.0). In the alternative,water soluble molybdenum compound may be substituted for the trivalentchromium compound as such molybdenum compounds may also be utilized ascorrosion resistant sealants. The solution may be applied or contactedupon the hard coated component 60 using any one of a number of processesincluding but not limited to immersion, spraying, painting, and the likeas known to one of ordinary skill in the art.

Experimental Section

Seven (7) panels of cold sprayed aluminum alloy 6061 on standardaluminum alloy 6061 (Panels 1-7) were processed to determine whether ornot the cold spray coating responds differently to processing. Testsperformed on the hard anodized panels per AMS 2469 were salt fog perASTM B-117, bond strength, and microstructural evaluation.

A small section of each Panel 1-7 was removed to perform metallographicexamination of the bond line between the cold spray aluminum 6061 layerand aluminum alloy 6061 substrate and the microstructural comparisonbetween the two (See Panel 1 of FIG. 4). Panels 1-7 submitted foranodized hard anodize were non-standard size for subsequent salt fogtesting ASTM B-117. Panels 1-7 were hard anodized per AMS 2469 (See FIG.5). Metallographic evaluation of the junction area of the anodized hardcoating and substrate did not reveal any evidence of crevice corrosionafter salt fog exposure (See FIG. 6).

Tensile bond tests were performed on each Panel 1-7 using Scotchweld2214 non-metallic filled epoxy, having a cure less than 300° F. (149°C.). The average ultimate strength (PSI) of each Panel 1-7 was 7,825 psiwith 100% rupture in the epoxy. These results are indicative of a goodbond between the coating and aluminum alloy 6061 panel and exceed thePWA 53-11 requirements of an average ultimate tensile bond strength ofat least 5000 psi.

The chemistry of the cold sprayed aluminum alloy 6061 deposited materialwas the same as standard aluminum alloy 6061 material of the panels.However, the metallurgical structure was different between the coldsprayed aluminum alloy layer and the parent aluminum alloy panel. Thecold sprayed aluminum alloy layer responded to the hard anodize processthe same as the parent aluminum alloy. Satisfactory coatings weregenerated using typical 6061 parameters and there was no noticeabledifference in the coating in the interface where the base 6061 materialand the cold sprayed 6061 met. There was no discernible loss in salt fogtest performance and no difference at the interface of the base metaland coating. Hardness measurements in the hard anodized area as well asthe base material and cold sprayed material were consistent with normalreadings for this material. The tensile bond strength specimens allfailed in the epoxy indicative of good adhesion of the coating. Thesetests confirmed that hard anodize of cold sprayed aluminum alloy 6061 isa viable candidate for repairing aluminum structures.

One or more embodiments of the present invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.Accordingly, other embodiments are within the scope of the followingclaims.

1. A process for repairing components, comprising the steps of:providing a component having an affected area on a surface of acomponent to be repaired; depositing a repair material over saidaffected area on said surface of said component so that said repairmaterial plastically deforms without melting and bonds to said affectedarea upon impact with said affected area and thereby covers saidaffected area; providing a sulfuric acid based anodizing solution;anodizing a deposited repair material on said surface of said componentin said sulfuric acid based anodizing solution; consuming only a portionof said deposited repair material to form a hard anodized coating layerupon said deposited repair material to form a hard anodized coatedcomponent; providing a corrosion resistant sealant solution; andcontacting a hard anodized coated component with the corrosion resistantsealant solution to form a corrosion resistant sealant coating on thehard anodized coated component.
 2. The process of claim 1, wherein saidrepair material comprises any one of the following: pure aluminum,aluminum alloy 6061, aluminum alloy 2219, aluminum alloy 5056, Al-12Sialloy, Al—Sc alloy, and aluminum alloy 6061/B4C.
 3. The process of claim1, wherein depositing said repair material comprises cold spraying saidrepair material.
 4. The process of claim 1, wherein said depositing stepcomprises providing said repair material in powder form having aparticle size in the range of from 5 microns to 50 microns.
 5. Theprocess of claim 1, wherein said depositing step further comprisesaccelerating said powder particles to a speed in the range of from 825m/s to 1400 m/s.
 6. The process of claim 1, further comprisingmechanically removing at least one of corrosion pits and damaged areasfrom said affected area on said component prior to performing saiddepositing step.
 7. The process of claim 6, further comprisingchemically cleaning said affected area on said component after saidremoval step.
 8. The process of claim 7, further comprising gritblasting a chemically cleaned affected area of said component after saidcleaning step.
 9. The process of claim 1, further comprising stressrelieving said component with said deposited repair material at atemperature and for a time sufficient to recover ductility for saiddeposited aluminum containing repair material prior to performing saidanodizing step.
 10. The process of claim 1, further comprisingdetermining a wear resistance of said deposited repair material on saidsurface of said component prior to performing said anodizing step. 11.The process of claim 10, further comprising performing a finalinspection of said component.
 12. The process of claim 10, furthercomprising determining a corrosion resistance of said anodized componentprior to providing said chromate conversion solution.
 13. The process ofclaim 1, wherein providing said corrosion resistant sealant solutioncomprises providing a chromate conversion solution or a molybdenumconversion solution.
 14. A repaired component, comprising: a componentincluding a surface having a cold sprayed layer of repair materialdisposed thereupon, said component further includes an originalthickness and said surface includes a restored thickness; and ananodized, hard coat disposed upon said cold sprayed layer, wherein saidoriginal thickness is a thickness of said component prior to applyingsaid cold sprayed layer and said restored thickness is said originalthickness combined with a thickness of said cold sprayed layer.
 15. Therepaired component of claim 14, wherein said component comprises any oneof the following: aluminum alloy, a magnesium alloy, conductive alloyand combinations thereof.